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Production Control.

Control comes in after,


a particular plan has
been made for
implementation.
Production Control, Introduction

 It is one of the most important and


fundamental function of an enterprise.
 It ensures desired output as per specified
quality, quantity and timings in most
economical way.
 Planning prescribes and outlines the
objectives and provide guidelines.
Production Control, Introduction

 It’s the production control which directs and


regulates all activities of production process.
 Control is a management process which
constrains events to follow plans.
 Control is a dynamic activity which sees that
facilities and personnel are economically
utilized and the products are manufactured
within the time and cost limits.
Production Control.

 Dictionary meaning of Control is to organize


or to Check and Regulate.
 Definition.

“ Control is maintaining a balance


in activities towards a goal or set
of goals evolved during production
planning.”
 Control is necessity, not luxury,
 Control is investment not expense.
Production Control.

 Objectives (Functions) of PC dept.


ii. Provision of Raw M, Machines and Labor.
iii. Organize production as per demand.
iv. OUR, to minimize cost and meet delivery.
v. Economize prod. and minimize setup cost.
vi. Co-ordination of various operations.
vii. Ensure timely supply of raw material of
desired Qlty and Qty, to avoid delay.
Production Control.

 Contd…
ii. Perform inspection of semi-finished and
finished goods and use quality control
techniques.
iii. Responsible for product design and
development.
Production Control.

 Factors Determining Production Control


Operations.

3. Nature of Production.
4. Nature of activities.
5. Magnitude of operation.
Production Control.

 LEVELS of PRODUCTION CONTROL.


2. Programming
3. Ordering
4. Dispatching
5. Progressing/ Follow up
6. Inventory control.
Levels/ Techniques of Prod. Control

 Programming.
 Regulates the supply of finished product in
desired amount at due date as per plans.
 It ensures most efficient use of labor,
equipment and capital.
 There are 3 main decisions involved in
Programming Viz.
Levels/ Techniques of Prod. Control

 DECISIONS

3. Nature of product to be manufactured.


4. Amount of quantities to be produced.
5. When to produce.
Levels/ Techniques of Prod. Control

 Objectives of Production Programming.

3. Reliable delivery to customer.


4. EVEN loading of plant.
5. EVEN loading of Labor in hours per week.
6. Efficient use of Capital.
Ex:- layout of Production program.
Levels/ Techniques of Prod. Control

 In preparation of Production program 3


main problems are solved.
2. Smoothing of seasonal sales demand.
3. Choice of batch quantity and batch
frequency for products, as per requirement.
4. Constant revision of production Program to
keep in line with the sales program.
Levels/ Techniques of Prod. Control

I. ORDERING
– It is the process of placing orders to the
suppliers and processing departments for the
materials required in such a way that all items
are delivered in time to meet the production
program.
– The order authorizing production is what has
come to be known as WORKS order. It is
derived from master schedule and operation
sheets.
Levels/ Techniques of Prod. Control

 2 information are required for each order


2. Requirement Quantity:-
 This information can be gathered from Master
Schedule.
3. Order Quantity:-
 Generally it is as same as Requirement Quantity
but sometimes for regular use higher quantity is
ordered.
 It is very critical decision to be taken.
Levels/ Techniques of Prod. Control

 Rules to be observed in ordering system

3. No work can be ordered without an order.


4. All orders should be in writing and in
standard form. (For purchase or manuf)
5. All orders should be issued by authorized
authority.
Levels/ Techniques of Prod. Control

 Following are main decisions in


Ordering.
2. Desired quantity of various components and
delivery date.
3. How much to order?
4. When to issue an order?
5. In what quantity parts should be procured.
6. Nature of Components (prodct, scrap,spare
Levels/ Techniques of Prod. Control
COMPONENTS OF ORDER FORM

 Order number.  Part Description


 Date of Order  Order Quantity
 Ordered by  Run Quantity
 Production Center.  Due Date
 Part number.  Material Source.
 Delivery instructions
Levels/ Techniques of Prod. Control

I. Dispatching.

 The decision of assigning various jobs to


different machines is known as dispatching
 Once the job is in the area where
operation is to be done, dispatching
decides where and by whom the job is to
done.
Levels/ Techniques of Prod. Control

 Functions of Dispatching.
2. To check immediate availability of R.M.
3. Ensuring all the production and inspection
aids are available for use.
4. Obtain appropriate specification list.
5. To collate jobs and all activities.
6. Processing inspection schedule.
Levels/ Techniques of Prod. Control

 Contd…
2. Assign work to proper man, machine & plc.
3. Issue necessary material when needed.
4. Issue production order note stating start and
finish times.
5. Return the acquired material at right place
and time.
6. Maintain all production records.
Levels/ Techniques of Prod. Control
important documents in production control through
dispatching.

1. Job order  Collection of time


2. Store requisition tickets at the end of
3. Issue of tool orders operations.
 Recording idle times
4. Issue of time
of machines.
tickets
 Internal delivery
5. Issue of inspection
orders. notes of finished
goods and R.M.
back to stores.
Levels/ Techniques of Prod. Control

I. Progressing or Follow-up.

 It is checking of production activities


systematically so that production is carried
out as per plans.
 It is a function by which one can give an
early warning when actual production is
deviating from planned production.
Levels/ Techniques of Prod. Control

 NECESSITY / IMPORTANCE of Follow-up


2. Failure to deliver material on time.
3. Machine/Power break-down.
4. Employees absenteeism.
5. Errors of design, planning or human activity
6. Unnecessary delays/ bottlenecks.
Levels/ Techniques of Prod. Control

 Generally specialists known as progress


chasers act as watch-dogs, doing..

3. Checking the progress continuously


4. Cause of discrepancy, if any in performance
5. Authorizing and signing requisitions.
6. Liason with other departments.
Levels/ Techniques of Prod. Control

 Steps in Progressing or Follow-up.

3. Flow charts indicating the planned


sequence of operations.
4. Production schedules to compare actual
with targets.
5. Machine loading charts.
6. Inspection schedules to check deviations.
Levels/ Techniques of Prod. Control

I. INVENTORY CONTROL
 Inventory for any organization is necessary
evil and requires careful planning.
 Components of Inventory are:-
4. All materials, parts, WIP or finished goods
recorded & kept it stores or warehouse.
5. List of quantities/monetary values for all
goods.
Levels/ Techniques of Prod. Control

 OBJECTIVES of Inventory Control.

3. Protection against fluctuation in demand.


4. Better use of Men, Machines and Materials.
5. Protection against Fluctuation in Output.
Levels/ Techniques of Prod. Control

 Inventory Control solves out 3 major issues,

3. Optimum amount of inventory to be carried


4. Economic Lot Size.
5. Choice of an Ideal system of inventory
control.